Surface cleaning apparatus with an arrester plate having a variable gap

ABSTRACT

A surface cleaning apparatus has a cyclone chamber having a longitudinal cyclone axis of rotation wherein the dirt outlet is defined by a gap between the sidewall of the cyclone and a plate positioned at the dirt outlet end of the cyclone.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/100,624, filed on Aug. 10, 2018 (now allowed), which itself is acontinuation-in-part of U.S. patent application Ser. No. 15/937,220filed on Mar. 27, 2018, the disclosure of which is incorporated hereinby reference.

FIELD

This disclosure relates generally to surface cleaning apparatus. In apreferred embodiment, the surface cleaning apparatus comprises acyclonic separator including a plate (also referred to as an arresterplate) at the dirt outlet end of a cyclone chamber.

INTRODUCTION

The following is not an admission that anything discussed below is partof the prior art or part of the common general knowledge of a personskilled in the art.

Various types of surface cleaning apparatus are known. Such surfacecleaning apparatus include vacuum cleaners, including upright vacuumcleaners, hand carriable vacuum cleaners, canister-type vacuum cleanersand Shop-Vac™ type vacuum cleaners. Some vacuum cleaners include acyclonic separator (also referred to as a cyclone bin assembly) having acyclone chamber, a dirt collection chamber, and a plate at the dirtoutlet end. See for example Conrad (U.S. Pat. No. 8,640,304).

SUMMARY

This summary is intended to introduce the reader to the more detaileddescription that follows and not to limit or define any claimed or asyet unclaimed invention. One or more inventions may reside in anycombination or sub-combination of the elements or process stepsdisclosed in any part of this document including its claims and figures.

During operation of a surface cleaning apparatus that uses a cyclonechamber with a dirt collection chamber exterior to the cyclone chamber,dirt particles that are entrained in an air stream entering a surfacecleaning apparatus and which are disentrained during the passage of airthrough the cyclone chamber may exit the cyclone chamber via a dirtoutlet and enter the dirt collection chamber. Dirt particles that arelarger than the size of the dirt outlet (e.g., popcorn) may tend toaccumulate in the cyclone chamber. If a sufficient amount of larger dirtparticles accumulate in the cyclone chamber, this may reduce the dirtseparation efficiency of the cyclone chamber. In order to permit thelarger dirt particles to exit the cyclone chamber, the size of the dirtoutlet may be increased. However, as the size of the dirt outlet isincreased, the dirt separation efficiency of the cyclone chamber may bereduced. As set out in this disclosure, the dirt outlet may haveportions having a different size. Accordingly, the dirt outlet maycomprise a gap or spacing between an end wall of the cyclone chamber andthe sidewall of the cyclone chamber. This gap or spacing may extend allthe way around the perimeter of the end wall (which may be referred toas a plate and may be a moveably mounted plate). The gap or spacing mayhave one or more portions which have a larger size (e.g., in the axialor vertical direction of the cyclone axis of rotation and/or a directionat an angle to the cyclone axis of rotation). This gap or spacing may beachieved by having the plate stepped in the axial direction and/or theplate having a non-circular shape (e.g., oval, D-shaped and differentdiameters in different directions).

According to a first aspect of this disclosure, which may be used byitself or in combination with one or more other aspects of thisdisclosure, a cyclone is provided at the dirt outlet end of the cyclonechamber with a plate that is stepped in the axial direction. The dirtoutlet is defined at least in part by a gap between the plate and thesidewall of the cyclone chamber. Stepping the plate in the axialdirection enables a portion of the plate to define a larger dirt outletso as to enable larger dirt to exit the cyclone chamber.

In accordance with this aspect, there is provided a surface cleaningapparatus comprising:

-   -   (a) an air flow path extending from a dirty air inlet to a clean        air outlet;    -   (b) a cyclone and a suction motor provided in the air flow path;    -   (c) the cyclone comprising a cyclone chamber having a central        longitudinal axis, the cyclone having a first end having a first        end wall, an axially spaced apart second end, a cyclone chamber        sidewall located between the first and second ends, a cyclone        air inlet provided at the first end, a cyclone air outlet        provided at the first end and a dirt outlet provided at the        second end, wherein a reference plane that is perpendicular to        the central longitudinal axis extends through the cyclone        chamber; and,    -   (d) a plate located at the second end, the plate having,        -   (i) a plate perimeter, a first portion, a second portion and            a transition portion provided between the first and second            portions, each of the first, second and transition portions            of the plate having a cyclone chamber face wherein the            cyclone chamber faces of the first and second portions of            the plate face towards the first end and border different            portions of the plate perimeter,        -   (ii) the second portion is spaced in a direction parallel to            the central longitudinal axis further from the reference            plane than the first portion,        -   (iii) the dirt outlet comprises a spacing between the            cyclone chamber sidewall and the second portion of the            plate,        -   (iv) the plate also having a dirt chamber face and a step            volume, the step volume positioned axially between the            cyclone chamber faces of the first and transition portions            and the dirt chamber face whereby the dirt chamber face            comprises a closure portion which underlies the step volume;            and,

(e) a dirt collection region in communication with the cyclone chambervia the dirt outlet.

In any embodiment, the closure portion may extend at an angle to thecentral longitudinal axis.

In any embodiment, the first portion of the plate may be thicker thanthe second portion of the plate.

In any embodiment, a thickness of the first portion of the plate mayincrease towards the transition portion of the plate.

In any embodiment, a first discontinuity may be provided between thecyclone chamber face of the first portion of the plate and the cyclonechamber face of the transition portion and a second discontinuity may beprovided between the cyclone chamber face of the transition portion andthe cyclone chamber face of the second portion of the plate.

In any embodiment, the transition portion may extend generally axially.

In any embodiment, the first portion of the plate and the second portionof the plate may be generally planar.

In any embodiment, the dirt chamber face of the plate may be generallycontinuous.

In any embodiment, the dirt collection region may be axially spaced fromand opposed to the first end of the cyclone.

In any embodiment, the closure portion may be planar.

In any embodiment, the closure portion may extend from a first endproximate a dirt chamber face of the second portion towards or acrossthe central longitudinal axis to a second end, and the first end of theclosure portion may be laterally spaced from the second end of theclosure portion.

In accordance with this aspect, there is also provided a surfacecleaning apparatus comprising:

-   -   (a) an air flow path extending from a dirty air inlet to a clean        air outlet and including a cyclone chamber and a suction motor;    -   (b) a dirt collection region external to the cyclone chamber;        and,    -   (c) a plate positioned between the cyclone chamber and the dirt        collection region and defining a dirt outlet from the cyclone        chamber to the dirt collection region, the plate having a        cyclone chamber face facing the cyclone chamber, an opposed dirt        collection face facing the dirt collection region, and first,        second, and transition portions, wherein cyclone chamber faces        of the first and second portions are connected by a cyclone        chamber face of the transition portion and are different axial        distances from a transverse plane that extends through the        cyclone and that is perpendicular to a central longitudinal axis        of the cyclone, and the dirt collection face closes a step        volume bordered by the first and transition portions.

In any embodiment, the first portion of the plate may be thicker thanthe second portion of the plate.

In any embodiment, the dirt chamber face of the plate may be generallycontinuous.

In any embodiment, the dirt collection region may be axially spaced fromand opposed to the first end of the cyclone.

In any embodiment, a first discontinuity may be provided between thecyclone chamber face of the first portion of the plate and the cyclonechamber face of the second portion of the plate.

In any embodiment, the first portion of the plate and the second portionof the plate maybe generally planar.

In any embodiment, the closure portion may extend at an angle to thecentral longitudinal axis.

In any embodiment, the closure portion may be planar.

In any embodiment, the closure portion may extend from a first endproximate a dirt chamber face of the second portion towards or acrossthe central longitudinal axis to a second end, and the first end of theclosure portion may be laterally spaced from the second end of theclosure portion.

In accordance with another aspect, there is provided surface cleaningapparatus comprising:

-   -   (a) an air flow path extending from a dirty air inlet to a clean        air outlet    -   (b) a cyclone provided in the air flow path, the cyclone        comprising a cyclone chamber, a cyclone air inlet, a cyclone air        outlet, a dirt outlet, a central longitudinally extending axis,        the cyclone chamber having first and second axially opposed        ends;    -   (c) a suction motor positioned in the air flow path;    -   (d) a dirt collection region external to the cyclone chamber;        and,    -   (e) a plate positioned at the second end of the cyclone chamber,        the plate having a cyclone chamber face facing the cyclone        chamber, the cyclone chamber face having first and second        portions, wherein the first portion of the cyclone chamber face        and the second portion of the cyclone chamber face are different        axial distances from a transverse reference plane that extends        through the cyclone chamber and that is perpendicular to the        central longitudinally extending axis of the cyclone,    -   wherein an annular gap between the plate and the cyclone extends        around all of the plate and defines the dirt outlet of the        cyclone chamber.

In any embodiment, the annular gap may have a radial distance betweenthe plate and the cyclone and the radial distance may be constant.

In any embodiment, the annular gap may have a radial distance betweenthe plate and the cyclone and the radial distance may vary at differentlocations around the plate.

In any embodiment, the plate may have a perimeter and the perimeter mayextend generally continuously.

In any embodiment, the plate has a perimeter and the perimeter has twodiscontinuities.

In any embodiment, the plate may have a segment removed. Optionally, theannular gap may have a radial distance between the plate and thecyclone, the radial distance may vary at different locations around theplate and the radial distance may be increased at a location of theplate from which the segment has been removed. Alternately, or inaddition, the second portion may be a greater axial distance from thetransverse plane than the first portion and the location of the platefrom which the segment has been removed may be the second portion.

In any embodiment, the second portion may be a greater axial distancefrom the transverse plane than the first portion and the second portionhas a segment removed. Optionally, the annular gap may have a radialdistance between the plate and the cyclone and the radial distance maybe increased at a location of removal of the segment.

In any embodiment, the plate may be positioned between the cyclonechamber and the dirt collection region, the plate may have a dirtcollection face facing the dirt collection region.

In any embodiment, the cyclone air inlet and the cyclone air outlet maybe provided at the first end of the cyclone chamber, the cyclone airoutlet may comprise a vortex finder and porous member positioned betweenthe cyclone chamber and an inlet of the vortex finder, and the vortexfinder and porous member may be spaced from the cyclone chamber face ofthe plate.

In any embodiment, the plate may be moveably mounted between a closedposition, in which the plate is positioned for operation of the cycloneand an open position wherein the plate is moved to provide access to thecyclone chamber.

In any embodiment, the dirt collection region has an end wall facing theplate and the end wall may be openable. Optionally, the plate may besupported by the end wall and is moveable with the end wall.

In any embodiment, the plate has a dirt collection face facing the dirtcollection region and the surface cleaning apparatus may furthercomprise a support member extending between the end wall and the dirtcollection face. Optionally, the cyclone air inlet and the cyclone airoutlet may be provided at the first end of the cyclone chamber, thecyclone air outlet may comprise a vortex finder and porous memberpositioned between the cyclone chamber and an inlet of the vortexfinder, and the vortex finder and porous member may be spaced from thecyclone chamber face of the plate.

In any embodiment, the plate has a perimeter, the cyclone has agenerally axially extending sidewall and the annular gap may be providedbetween the perimeter of the plate and the sidewall.

In any embodiment, the cyclone has an axially extending sidewall and thesidewall has an end face and at least a portion of the end wall may facethe plate. Optionally, the plate has a perimeter, the dirt collectionregion has a sidewall and the annular gap may be provided between theperimeter of the plate and the sidewall.

According to another aspect of this disclosure, which may be used byitself or in combination with one or more other aspects of thisdisclosure, a cyclone is provided at the dirt outlet end of the cyclonechamber wherein the dirt outlet is formed by a variable spacing betweenthe cyclone sidewall and a plate wherein the variable spacing is formedby varying the shape of the plate and/or the distance between the plateand the inlet end of the cyclone chamber.

In accordance with this aspect, there is provided a surface cleaningapparatus comprising:

-   -   (a) an air flow path extending from a dirty air inlet to a clean        air outlet;    -   (b) a cyclone and a suction motor provided in the air flow path;    -   (c) the cyclone comprising a cyclone chamber having a central        longitudinal axis, the cyclone having a first end having a first        end wall, an axially spaced apart second end, a cyclone chamber        sidewall located between the first and second ends, a cyclone        air inlet provided at the first end, a cyclone air outlet        provided at the first end and a dirt outlet provided at the        second end, wherein the first end of the cyclone chamber        sidewall is located at the first end of the cyclone and the        second end of the sidewall is spaced from the first end;    -   (d) a plate located at the second end, the plate having a plate        perimeter, a cyclone chamber face that faces towards the first        end; and,    -   (e) a dirt collection region in communication with the cyclone        chamber via the dirt outlet,    -   wherein the dirt outlet comprises a spacing between the cyclone        chamber sidewall and the plate, which spacing extends around the        entire plate perimeter, and    -   wherein the spacing comprises a first portion that extends        around a first portion of the perimeter and a second portion        that extends around a second portion of the perimeter, wherein        the second portion of the spacing has a larger length in at        least one of the following directions:        -   (i) a vertical direction in a plane of the sidewall; and,        -   (ii) a radial direction in a plane of the plate, and    -   wherein the larger length is produced by at least one of:        -   (iii) a second part of the plate defining the second portion            of the perimeter of the plate having a different diameter            than a diameter of a first part of the plate defining the            first portion of the perimeter of the plate; and,        -   (iv) the second part the plate having a greater distance            between the cyclone chamber face of the plate and the first            end of the cyclone chamber than a distance of the first part            of the plate and the first end of the cyclone chamber.

In any embodiment, a projection of the sidewall may intersect the plateand the spacing may comprise a gap between the second end of thesidewall and the cyclone chamber face of the plate.

In any embodiment, the larger length may be produced by the second partof the plate having a greater distance between the cyclone chamber faceof the plate and the first end of the cyclone chamber than a distance ofthe first part of the plate and the first end of the cyclone chamber.

In any embodiment, the larger length may also be produced by a portionof the sidewall located at the second portion having a shorter axiallength than another portion of the sidewall.

In any embodiment, the plate may have a smaller diameter that a diameterof the cyclone chamber whereby a projection of the sidewall extendsradially outwardly of the plate and the spacing comprises a gap betweenthe perimeter of the plate and the sidewall.

In any embodiment, the larger length may be produced by the second partof the plate having a different diameter than a diameter of the firstpart of the plate.

In any embodiment, the second portion of the perimeter of the plate maybe generally linear.

In any embodiment, the second portion of the perimeter of the plate maybe stepped inwardly in the plane of the plate from the first portion ofthe perimeter of the plate.

In any embodiment, the perimeter of the plate may face the sidewall.

In any embodiment, the plate may be positioned axially spaced below thesecond end of the sidewall.

In any embodiment, a projection of the sidewall may intersect only apart of the plate and the spacing may comprise a vertically extendinggap between the second end of the sidewall and the cyclone chamber faceof the plate and a radially extending gap between the perimeter of theplate and the sidewall.

In any embodiment, the larger length may be produced by the second partof the perimeter of the plate having a greater distance between thecyclone chamber face of the plate and the first end of the cyclonechamber than a distance of the first part of the plate and the first endof the cyclone chamber and by the second part of the plate having adifferent diameter than a diameter of the first part of the plate.

In any embodiment, the larger length may also be produced by a portionof the sidewall located at the second portion having a shorter axiallength than another portion of the sidewall.

In any embodiment, the second portion of the perimeter of the plate maybe generally linear.

In any embodiment, the second portion of the perimeter of the plate maybe stepped inwardly in the plane of the plate from the first portion ofthe perimeter of the plate.

In any embodiment, the perimeter of the plate may face the sidewall.

In any embodiment, the plate may be positioned axially spaced below thesecond end of the sidewall.

In any embodiment, the dirt collection chamber may be located below theplate.

DRAWINGS

The drawings included herewith are for illustrating various examples ofarticles, methods, and apparatus of the teaching of the presentspecification and are not intended to limit the scope of what is taughtin any way.

In the drawings:

FIG. 1 is a perspective view of a surface cleaning apparatus inaccordance with an embodiment;

FIG. 2 is a cross-sectional view taken along line 2-2 in FIG. 1;

FIG. 3 is a cross-sectional view taken along line 2-2 in FIG. 1 of acyclone bin assembly of the surface cleaning apparatus of FIG. 1 whenremoved from the remainder of the surface cleaning apparatus;

FIG. 4 is a top perspective view of an arrester plate of the cyclone binassembly of FIG. 3;

FIG. 5 is a bottom perspective view of the arrester plate of FIG. 4;

FIG. 6 is the cross-sectional view of FIG. 3 with the cyclone binassembly in an open position;

FIG. 7 is a cross-sectional view of a cyclone bin assembly having anarrester plate in accordance with another embodiment;

FIG. 8 is a cross-sectional view of a cyclone bin assembly having anarrester plate in accordance with another embodiment;

FIG. 9 is a cross-sectional view taken along line 9-9 in FIG. 8;

FIG. 10 is a cross-sectional view taken along line 9-9 in FIG. 8 with anarrester plate in accordance with another embodiment;

FIG. 11 is a cross-sectional view a cyclone bin assembly with anarrester plate in accordance with another embodiment;

FIG. 12 is a top perspective view of the arrester plate of the cyclonebin assembly of FIG. 11;

FIG. 13 is a bottom perspective view of the arrester plate of thecyclone bin assembly of FIG. 11;

FIG. 14 is a cross-sectional view a cyclone bin assembly with anarrester plate in accordance with another embodiment;

FIG. 15 is a top perspective view of the arrester plate of the cyclonebin assembly of FIG. 14;

FIG. 16 is a bottom perspective view of the arrester plate of thecyclone bin assembly of FIG. 14;

FIG. 17 is a cross-sectional view a cyclone bin assembly with anarrester plate in accordance with another embodiment;

FIG. 18 is a top perspective view of the arrester plate of the cyclonebin assembly of FIG. 17;

FIG. 19 is a bottom perspective view of the arrester plate of thecyclone bin assembly of FIG. 17.

FIG. 20 is a cross-sectional view of a cyclone bin assembly lookingrearwardly, the cyclone bin assembly having an arrester plate and acyclone chamber sidewall defining a cyclone dirt outlet in accordancewith another embodiment;

FIG. 21 is a cross-sectional view of the cyclone bin assembly of FIG. 20looking towards one side of the cyclone bin assembly;

FIG. 22 is a perspective cross-sectional view from above of the cyclonebin assembly of FIG. 20;

FIG. 23A is a cross-sectional view of the cyclone bin assembly of FIG.20 as indicated by line 23A-23A in FIG. 21;

FIG. 23B is a cross-sectional view of the cyclone bin assembly of FIG.20 as indicated by line 23B on FIG. 21;

FIG. 24 is a perspective cross-sectional view from below of the cyclonebin assembly of FIG. 20;

FIG. 25 is a cross-sectional view of a cyclone bin assembly having anarrester plate and cyclone chamber sidewall defining a cyclone dirtoutlet in accordance with another embodiment;

FIG. 26 is a cross-sectional view of a cyclone bin assembly having anarrester plate and cyclone chamber sidewall defining a cyclone dirtoutlet in accordance with another embodiment;

FIG. 27 is a cross-sectional view of a cyclone bin assembly having anarrester plate and cyclone chamber sidewall defining a cyclone dirtoutlet in accordance with another embodiment;

FIG. 28 is a cross-sectional view of a cyclone bin assembly having anarrester plate and cyclone chamber sidewall defining a cyclone dirtoutlet in accordance with another embodiment;

FIG. 29 is a cross-sectional view of a cyclone bin assembly having anarrester plate and cyclone chamber sidewall defining a cyclone dirtoutlet in accordance with another embodiment;

FIG. 30 is a cross-sectional view of a cyclone bin assembly having anarrester plate and cyclone chamber sidewall defining a cyclone dirtoutlet in accordance with another embodiment;

FIG. 31 is a cross-sectional view of a cyclone bin assembly having anarrester plate and cyclone chamber sidewall defining a cyclone dirtoutlet in accordance with another embodiment;

FIG. 32A is a cross-sectional view of a cyclone bin assembly lookingtowards a side of the cyclone bin assembly, the cyclone bin assemblyhaving a D-shaped arrester plate and cyclone chamber sidewall defining acyclone dirt outlet in accordance with another embodiment;

FIG. 32B is a cross-sectional view of the cyclone bin assembly of FIG.32A looking downwards at the arrester plate along a similar line asindicated by line 23A-23A in FIG. 21;

FIG. 33A is a cross-sectional view of a cyclone bin assembly lookingtowards a side of the cyclone bin assembly, the cyclone bin assemblyhaving an arrester plate and cyclone chamber sidewall defining a cyclonedirt outlet in accordance with another embodiment;

FIG. 33B is a cross-sectional view of the cyclone bin assembly of FIG.33A looking downwards at the arrester plate along a similar line asindicated by line 23A-23A in FIG. 21;

FIG. 34A is a cross-sectional view of a cyclone bin assembly lookingtowards a side of the cyclone bin assembly, the cyclone bin assemblyhaving an arrester plate and cyclone chamber sidewall defining a cyclonedirt outlet in accordance with another embodiment;

FIG. 34B is a cross-sectional view of the cyclone bin assembly of FIG.34A looking downwards at the arrester plate along a similar line asindicated by line 23A-23A in FIG. 21;

FIG. 35A is a cross-sectional view of a cyclone bin assembly lookingtowards a side of the cyclone bin assembly, the cyclone bin assemblyhaving an arrester plate and cyclone chamber sidewall defining a cyclonedirt outlet in accordance with another embodiment;

FIG. 35B is a cross-sectional view of the cyclone bin assembly of FIG.35A looking downwards at the arrester plate along a similar line asindicated by line 23A-23A in FIG. 21;

FIG. 36A is a cross-sectional view of a cyclone bin assembly lookingtowards a side of the cyclone bin assembly, the cyclone bin assemblyhaving an arrester plate and cyclone chamber sidewall defining a cyclonedirt outlet in accordance with another embodiment;

FIG. 36B is a cross-sectional view of the cyclone bin assembly of FIG.36A looking downwards at the arrester plate along a similar line asindicated by line 23A-23A in FIG. 21;

FIG. 37A is a cross-sectional view of a cyclone bin assembly lookingtowards a side of the cyclone bin assembly, the cyclone bin assemblyhaving an arrester plate and cyclone chamber sidewall defining a cyclonedirt outlet in accordance with another embodiment;

FIG. 37B is a cross-sectional view of the cyclone bin assembly of FIG.37A looking downwards at the arrester plate along a similar line asindicated by line 23A-23A in FIG. 21;

FIG. 38A is a cross-sectional view of a cyclone bin assembly lookingtowards a side of the cyclone bin assembly, the cyclone bin assemblyhaving an arrester plate and cyclone chamber sidewall defining a cyclonedirt outlet in accordance with another embodiment;

FIG. 38B is a cross-sectional view of the cyclone bin assembly of FIG.38A looking downwards at the arrester plate along a similar line asindicated by line 23A-23A in FIG. 21;

FIG. 39A is a cross-sectional view of a cyclone bin assembly lookingtowards a side of the cyclone bin assembly, the cyclone bin assemblyhaving an arrester plate and cyclone chamber sidewall defining a cyclonedirt outlet in accordance with another embodiment; and,

FIG. 39B is a cross-sectional view of the cyclone bin assembly of FIG.39A looking downwards at the arrester plate along a similar line asindicated by line 23A-23A in FIG. 21.

DESCRIPTION OF VARIOUS EMBODIMENTS

Various apparatuses, methods and compositions are described below toprovide an example of an embodiment of each claimed invention. Noembodiment described below limits any claimed invention and any claimedinvention may cover apparatuses and methods that differ from thosedescribed below. The claimed inventions are not limited to apparatuses,methods and compositions having all of the features of any oneapparatus, method or composition described below or to features commonto multiple or all of the apparatuses, methods or compositions describedbelow. It is possible that an apparatus, method or composition describedbelow is not an embodiment of any claimed invention. Any inventiondisclosed in an apparatus, method or composition described below that isnot claimed in this document may be the subject matter of anotherprotective instrument, for example, a continuing patent application, andthe applicant(s), inventor(s) and/or owner(s) do not intend to abandon,disclaim, or dedicate to the public any such invention by its disclosurein this document.

The terms “an embodiment,” “embodiment,” “embodiments,” “theembodiment,” “the embodiments,” “one or more embodiments,” “someembodiments,” “one embodiment”, and the like mean “one or more (but notall) embodiments of the present invention(s),” unless expresslyspecified otherwise.

The terms “including,” “comprising” and variations thereof mean“including but not limited to,” unless expressly specified otherwise. Alisting of items does not imply that any or all of the items aremutually exclusive, unless expressly specified otherwise. The terms “a,”“an” and “the” mean “one or more,” unless expressly specified otherwise.

As used herein and in the claims, two or more parts are said to be“coupled”, “connected”, “attached”, “joined”, “affixed”, or “fastened”where the parts are joined or operate together either directly orindirectly (i.e., through one or more intermediate parts), so long as alink occurs. As used herein and in the claims, two or more parts aresaid to be “directly coupled”, “directly connected”, “directlyattached”, “directly joined”, “directly affixed”, or “directly fastened”where the parts are connected in physical contact with each other. Asused herein, two or more parts are said to be “rigidly coupled”,“rigidly connected”, “rigidly attached”, “rigidly joined”, “rigidlyaffixed”, or “rigidly fastened” where the parts are coupled so as tomove as one while maintaining a constant orientation relative to eachother. None of the terms “coupled”, “connected”, “attached”, “joined”,“affixed”, and “fastened” distinguish the manner in which two or moreparts are joined together.

Furthermore, it will be appreciated that for simplicity and clarity ofillustration, where considered appropriate, reference numerals may berepeated among the figures to indicate corresponding or analogouselements. In addition, numerous specific details are set forth in orderto provide a thorough understanding of the example embodiments describedherein. However, it will be understood by those of ordinary skill in theart that the example embodiments described herein may be practicedwithout these specific details. In other instances, well-known methods,procedures, and components have not been described in detail so as notto obscure the example embodiments described herein. In addition, thedescription is not to be considered as limiting the scope of the exampleembodiments described herein.

General Description of a Vacuum Cleaner

Referring to FIGS. 1-2, an exemplary embodiment of a surface cleaningapparatus is shown generally as 100. The following is a generaldiscussion of apparatus 100, which provides a basis for understandingseveral of the features, which are discussed herein. As discussedsubsequently, each of the features may be used individually or in anyparticular combination or sub-combination in this or in otherembodiments disclosed herein.

Embodiments described herein include an improved cyclone assembly 116,and a surface cleaning apparatus 100 including the same. Surfacecleaning apparatus 100 may be any type of cyclonic surface cleaningapparatus, including for example a hand vacuum cleaner, a stick vacuumcleaner, a canister vacuum cleaner, and an upright vacuum cleaner.

In FIGS. 1-2, surface cleaning apparatus 100 is illustrated as a handvacuum cleaner, which may also be referred to also as a “handvac” or“hand-held vacuum cleaner”. As used herein, a hand vacuum cleaner is avacuum cleaner that can be operated to clean a surface generallyone-handedly. That is, the entire weight of the vacuum may be held bythe same one hand used to direct a dirty air inlet of the vacuum cleanerwith respect to a surface to be cleaned. For example, handle 104 anddirty air inlet 108 may be rigidly coupled to each other (directly orindirectly), such as being integrally formed or separately molded andthen non-removably secured together such as by an adhesive or welding,so as to move as one while maintaining a constant orientation relativeto each other. This is to be contrasted with canister and upright vacuumcleaners, whose weight is typically supported by a surface (e.g. afloor) during use, and when a canister vacuum cleaner is operated orwhen an upright vacuum cleaner is operated in a ‘lift-away’configuration, a second hand is typically required to direct the dirtyair inlet at the end of a flexible hose.

Still referring to FIGS. 1-2, surface cleaning apparatus 100 includes amain body 112 having an air treatment member 116 (which may bepermanently affixed to the main body or may be removable therefrom foremptying), a dirty air inlet 108, a clean air outlet 120, and an airflow path 124 extending between the dirty air inlet 108 and the cleanair outlet 120.

Surface cleaning apparatus 100 has a front end 128, a rear end 132, anupper end (also referred to as the top) 136, and a lower end (alsoreferred to as the bottom) 140. In the embodiment shown, dirty air inlet108 is at an upper portion of apparatus front end 128 and clean airoutlet 120 is at a rearward portion of apparatus 100 at apparatus rearend 132. It will be appreciated that dirty air inlet 108 and clean airoutlet 120 may be positioned in different locations of apparatus 100.

A suction motor 144 is provided to generate vacuum suction throughairflow path 124, and is positioned within a motor housing 148. Suctionmotor 144 may be a fan-motor assembly including an electric motor andimpeller blade(s). In the illustrated embodiment, suction motor 144 ispositioned in the air flow path 124 downstream of air treatment member116. In this configuration, suction motor 144 may be referred to as a“clean air motor”. Alternatively, suction motor 144 may be positionedupstream of air treatment member 116, and referred to as a “dirty airmotor”.

Air treatment member 116 is configured to remove particles of dirt andother debris from the air flow. In the illustrated example, airtreatment member 116 includes a cyclone assembly (also referred to as a“cyclone bin assembly”) having a single cyclonic cleaning stage with asingle cyclone 152 and a dirt collection chamber 156 (also referred toas a “dirt collection region”, “dirt collection bin”, “dirt bin”, or“dirt chamber”). Cyclone 152 has a cyclone chamber 154, and dirtcollection chamber 156 may be external to the cyclone chamber 154 (i.e.dirt collection chamber 156 may have a discrete volume from that ofcyclone chamber 154). Cyclone 152 and dirt collection chamber 156 may beof any configuration suitable for separating dirt from an air stream andcollecting the separated dirt, respectively and may be in communicationby a dirt outlet of the cyclone chamber.

In alternate embodiments, air treatment member 116 may include a cycloneassembly having two or more cyclonic cleaning stages arranged in serieswith each other. Each cyclonic cleaning stage may include one or morecyclones arranged in parallel with each other and one or more dirtcollection chambers, of any suitable configuration. The dirt collectionchamber(s) may be external to the cyclone chambers of the cyclones.

Alternatively, one or more (or all) of the dirt collection chamber(s)may be internal to one or more (or all) of the cyclone chambers. Forexample, the internal dirt collection chamber(s) may be configured as adirt collection area within the cyclone chamber.

Referring to FIG. 2, hand vacuum cleaner 100 may include a pre-motorfilter 160 provided in the air flow path 124 downstream of air treatmentmember 116 and upstream of suction motor 144. Pre-motor filter 160 maybe formed from any suitable physical, porous filter media. For example,pre-motor filter 160 may be one or more of a foam filter, felt filter,HEPA filter, or other physical filter media. In some embodiments,pre-motor filter 160 may include an electrostatic filter, or the like.As shown, pre-motor filter 160 may be located in a pre-motor filterhousing 164 that is external to the air treatment member 116.

In the illustrated embodiment, dirty air inlet 108 is the inlet end 168of an air inlet conduit 172. Optionally, inlet end 168 of air inletconduit 172 can be used as a nozzle to directly clean a surface.Alternatively, or in addition to functioning as a nozzle, air inletconduit 172 may be connected (e.g. directly connected) to the downstreamend of any suitable accessory tool such as a rigid air flow conduit(e.g., an above floor cleaning wand), a crevice tool, a mini brush, andthe like. As shown, dirty air inlet 108 may be positioned forward of airtreatment member 116, although this need not be the case.

In the embodiment of FIG. 2, the air treatment member 116 comprises acyclone 152, the air treatment air inlet is a cyclone air inlet 184, andthe air treatment member air outlet is a cyclone air outlet 188.Accordingly, in operation, after activating suction motor 144, dirty airenters apparatus 100 through dirty air inlet 108 and is directed alongair inlet conduit 172 to the cyclone air inlet 184. As shown, cycloneair inlet 184 may direct the dirty air flow to enter cyclone chamber 154in a tangential direction so as to promote cyclonic action. Dirtparticles and other debris may be disentrained (i.e. separated) from thedirty air flow as the dirty air flow travels from cyclone air inlet 184to cyclone air outlet 188. The disentrained dirt particles and debrismay discharge from cyclone chamber 154 through a dirt outlet 190 intodirt collection chamber 156 external to the cyclone chamber 154, wherethe dirt particles and debris may collect until dirt collection chamber156 is emptied.

Air exiting cyclone chamber 154 may pass through an outlet passage 192located upstream of cyclone air outlet 188. Cyclone chamber outletpassage 192, may also act as a vortex finder to promote cyclonic flowwithin cyclone chamber 154. In some embodiments, cyclone outlet passage192 may include a porous member such as a screen or shroud 196 (e.g. afine mesh screen) in the air flow path 124 (e.g., positioned between thecyclone chamber and an inlet of the vortex finder) to remove large dirtparticles and debris, such as hair, remaining in the exiting air flow.The vortex finder and porous member may be spaced from the cyclonechamber face of plate 216. It will be appreciated that, in someembodiments, only a screen may be provided. Alternately, a vortex findermay be provided without a screen or the like.

From cyclone air outlet 188, the air flow may be directed into pre-motorfilter housing 164 at an upstream side 204 of pre-motor filter 160. Theair flow may pass through pre-motor filter 160 to pre-motor filterdownstream side 208, and then exit through pre-motor filter chamber airoutlet 212 into motor housing 148. At motor housing 148, the clean airflow may be drawn into suction motor 144 and then discharged fromapparatus 100 through clean air outlet 120.

The following is a description of various dirt outlets that are definedby a gap or spacing between a dirt arrester plate (also referred to as a“dirt arrester”, “arrester plate”, or simply “plate”) and a cyclonechamber sidewall that may be used in any cyclone design. The plateseparates the cyclone chamber from the dirt collection chamber. Inaccordance with this feature, the dirt collection chamber is external tothe cyclone chamber. The spacing may extend around the entire perimeterof the plate or just a portion of the plate (e.g., a portion of theperimeter of the plate may abut a portion of the cyclone chambersidewall.

Various configurations of the spacing are described herein. In someembodiments, the shape of the perimeter of the plate may vary andprovides for a variable spacing in the radial direction between theperimeter of the plate and the cyclone chamber sidewall to form a gapextending radially between the perimeter of the plate and the cyclonechamber sidewall. In any such embodiment, it will be appreciated thatsome or all of the plate may be located radially inwardly from the innersurface of the cyclone chamber sidewall and/or some or all of the platemay be located axially spaced from the end wall of the cyclone chambersidewall. In other embodiments, the distance between the inlet end ofthe cyclone chamber and the plate may vary at different locations aroundthe perimeter of the plate. In any embodiment, the length of the cyclonechamber sidewall may vary around the perimeter of the plate.

Axially Stepped Arrester

In accordance with this feature, the dirt collection chamber is externalto the cyclone chamber and the dirt outlet from the cyclone chambercomprises or consists of an axially extending gap between the arresterplate and the cyclone chamber sidewall. In accordance with this feature,the arrester plate has an ‘axial step’, in which a portion of thearrester plate is axially recessed to create an axially recessed step.The axial step may create a relatively larger dirt outlet gap or spacingbetween the cyclone chamber sidewall and the stepped portion of thearrester plate periphery, which can allow larger debris to pass throughthe dirt outlet.

Without being limited by theory, as compared with an entirely planararrester plate having a generally uniformly sized dirt outlet gap, theaxially stepped arrester design may provide greater separationefficiency (i.e. percentage of dirt particles of a dirty air flowseparated from the air flow and retained in the dirt collection chamber)by permitting larger dirt particles to exit the cyclone chamber therebyreducing the likelihood that larger dirt particles in the cyclonechamber may produce eddy currents or otherwise interfere with the flowpattern in a cyclone chamber. Thus, the axially stepped arrester designmay allow the dirt collection chamber to admit large dirt particles(e.g. stones, dry foods, etc.) while providing a high separationefficiency.

In accordance with this design, at least one portion of the arresterplate is recessed axially to create a first portion of the spacing and asecond portion of the spacing, wherein the second portion of the spacinghas a greater distance between the cyclone chamber face of the plate andthe first or inlet end of the cyclone chamber than a distance of thefirst portion of the plate and the first end of the cyclone chamber.

Reference is now made to FIGS. 3-5. As shown, cyclone bin assembly 116includes an arrester plate 216 that separates cyclone chamber 154 fromdirt collection chamber 156. Arrester plate 216 also cooperates withcyclone 152 to define dirt outlet 190 from cyclone chamber 154 into dirtcollection chamber 156.

Arrester plate 216 may define at least part of an end wall for one orboth of cyclone 152 and dirt collection chamber 156. As shown, arresterplate 216 may have a cyclone chamber face 220 that borders cyclonechamber 154, and an opposite dirt chamber face 224 that borders dirtcollection chamber 156. Cyclone chamber face 220 may face towards aninterior volume of cyclone chamber 154. Similarly, dirt chamber face 224may face towards an interior volume of dirt collection chamber 156.

Cyclone 152 has a first end 228 having a first end wall 232, a secondend 236 axially spaced apart from first end 228, and a cyclone chambersidewall 240 positioned between the first and second ends 228 and 236.Cyclone 152 also has a central longitudinal axis 242 (also referred toas a “cyclone axis”) that extends from the first end 228 to the secondend 236. In the example shown, cyclone second end 236 may be defined atleast in part by cyclone chamber face 220 of arrester plate 216. In someembodiments, at least a portion of cyclone chamber face 220 faces (i.e.has a surface normal pointed towards) cyclone first end 228. It will beappreciated that, if plate 216 is spaced from sidewall 240, thensidewall 240 will not extend to plate 216. In some embodiments, aportion of plate 216 may abut portions of sidewall 240 while anotherportion, e.g., the stepped down portion, may be spaced from sidewall 240to define part or all of the dirt outlet.

Still referring to FIGS. 3-5, cyclone outlet passage 192 may define avortex finder that promotes cyclonic flow within cyclone chamber 154. Asshown, cyclone outlet passage 192 may extend from a first end 244 atcyclone first end 228, to a second end 248 within cyclone chamber 154.Cyclone outlet passage 192 has one or more inlet openings 252 that admitair exiting cyclone chamber 154 to enter cyclone outlet passage 192towards cyclone air outlet 188. Cyclone outlet passage opening(s) 252may be overlaid with a porous member 254 (e.g. a fine mesh screen),which may remove large dirt and debris from the air flow entering thecyclone outlet passage 192. As shown, cyclone outlet passage 192 andporous member 254 may be spaced (e.g. axially) from cyclone chamber face220 of arrester plate 216. Cyclone outlet passage 192 may be intersectedby cyclone axis 242. As shown, cyclone outlet passage 192 may have acentral longitudinal axis 256 that is parallel to cyclone axis 242 (e.g.collinear to cyclone axis 242, or spaced apart from cyclone axis 242).

It will be appreciated that any cyclone air outlet may be used and thatthe cyclone air outlet may be at various locations as is known in theart. Similarly, it will be appreciated that any cyclone air inlet 184may be used and that the cyclone air inlet may be at various locationsas is known in the art.

Dirt collection chamber 154 has a first end 260, a second end 264axially spaced apart from first end 260, and a sidewall 268 that extendsbetween the first and second ends 260 and 264. Dirt collection chamber154 has a longitudinal axis 272 (also referred to as a “dirt chamberaxis”). Dirt chamber axis 272 may be parallel to cyclone axis 242 (e.g.collinear to cyclone axis 242, or transversely spaced apart from cycloneaxis 242). Dirt chamber first end 260 may be defined at least in part bydirt chamber face 224 of arrester plate 216. Dirt chamber second end 264may include a second end wall 276. In some embodiments, at least aportion of dirt chamber face 224 faces (i.e. has a surface normallypointed towards) dirt chamber second end 264.

As used herein, the term “axial” and “axially” mean “in a directionparallel to the respective longitudinal axis”, such as for examplecyclone axis 242 or dirt chamber axis 272. For example, dirt chamberface 224 may be described as being axially spaced apart from cyclonechamber face 220 in that dirt chamber face 224 is spaced from cyclonechamber face 220 in a direction parallel to or along the cyclone axis242.

Referring to FIGS. 8-9, cyclone dirt outlet 190 may extend around all ofarrester plate periphery 288. As shown, every point on arrester plateperiphery 288 may have a (non-zero) dirt outlet gap length 292 tocyclone chamber sidewall 240. In this way, dirt outlet 190 may form acontinuous annular gap. This helps to mitigate the development ofblockages caused by an accumulation of debris at locations where thereis no dirt outlet 190, e.g. because the dirt outlet 190 is obstructed.In other embodiments, arrester plate 216 may about part of sidewall 240.

Referring to FIGS. 3 and 6, arrester plate 216 may be movable between aclosed position (FIG. 3) and an open position (FIG. 6). In the closedposition, arrester plate 216 may act to separate cyclone chamber 154from dirt collection chamber 156. If plate 216 contacts part of sidewall240, then arrester plate 216 may at least partially close cyclone secondend 236 when in the closed position. Alternately, as exemplified inFIGS. 3 and 8-10, plate 216 may be spaced from all of sidewall 240 whenin the closed position. In the open position, arrester plate 216 may bepositioned to provide user access to cyclone chamber 154 (e.g. forcleaning). For example, arrester plate 216 may close less of or none ofcyclone second end 236 when in the open position as compared to theclosed position.

As shown, arrester plate 216 may be connected to an openable end wall276 of dirt collection chamber 156. Arrester plate 216 may move with endwall 276 so that when end wall 276 is opened, arrester plate 216 isdisplaced from (i.e. moved away from) cyclone second end 236. Thisallows cyclone chamber 154 and dirt collection chamber 156 to be openedand emptied concurrently by moving end wall 276 from its closed position(FIG. 3) to its open position (FIG. 6). Alternately, plate 216 may bepivotally mounted to sidewall 240, to a sidewall of the dirt chamber,

In some embodiments, plate 216 may not be openable, or it may beopenable separately from the dirt chamber. For example, plate 216 may bepivotally mounted to sidewall 240 or to a sidewall of the dirt chamberand may have its own releasable lock. Accordingly, plate 216 may remainin position when end wall 276 is opened and may be separately openable.

Dirt chamber end wall 276 may be openable in any manner that allowsaccess to empty dirt collection chamber 156. For example, dirt chamberend wall 276 may be pivotally openable as shown, or removable from dirtcollection chamber 156. In the illustrated example, dirt chamber endwall 276 is rotatably connected to dirt collection chamber sidewall 268by a hinge 280, and releasably held in the closed position (FIG. 3) by alatch 284.

Arrester plate 216 may be connected to dirt chamber end wall 276 in anymanner that allows arrester plate 216 to open concurrently as dirtchamber end wall 276 is opened. In the illustrated example, arresterplate 216 is connected to dirt chamber end wall 276 by a rigidly mountedsupport member 286. Accordingly, support member 286 may be a post thatrigidly connects arrester plate 216 to dirt chamber end wall 276,whereby arrester plate 216 and dirt chamber end wall 276 move as one. Insome embodiments, support member 286 may be moveable (pivotally) mountedwith respect to end wall 276 and/or plate 216 may be moveable(pivotally) mounted with respect to support 268. As shown, supportmember 286 may extend from dirt chamber face 224 of arrester plate 216to dirt chamber end wall 276. In this example, at least a portion ofdirt chamber end wall 276 faces (i.e. has a surface normal pointedtowards) arrester plate 216 (e.g. towards dirt chamber face 224).

Returning to FIGS. 3-5, cyclone dirt outlet 190 may be formed by a gapbetween cyclone chamber sidewall 240 and the arrester plate 216). Dirtthat is disentrained (i.e. separated) from the airflow circulatingthrough cyclone chamber 154 (e.g. by cyclonic action within cyclonechamber 154) may exit cyclone chamber 154 through dirt outlet 190 intodirt collection chamber 156. The maximum size of a dirt particle thatcan exit through dirt outlet 190 is defined by a gap length 292. Gaplength 292 is the shortest distance between a given point on arresterplate 216 and cyclone chamber sidewall 240. There may be a uniform gaplength 292 at every point on arrester plate periphery 288, or gap length292 may vary along arrester plate periphery 288.

As exemplified in FIG. 3, plate 216 may have a diameter similar to thediameter of cyclone chamber 154 and the cyclone axis may intersect thecentre of arrester plate 216. Accordingly the arrester plate periphery288 (also referred to as “arrester plate perimeter”) may underlie thesidewall 240 (i.e., a projection of sidewall 240 may intersect thearrester plate periphery 288) such that arrester plate periphery 288underlies a free end 296 of cyclone chamber sidewall 240. Accordingly,as exemplified in FIG. 3, dirt outlet 190 is defined by a gap length292, which is solely axial. That is, the shortest distance between everypoint on arrester plate periphery 288 and cyclone chamber sidewall 240is in a direction parallel to cyclone axis 242.

It will be appreciated that the cross sectional area of plate 216 andthe outlet end of the cyclone chamber 154 may vary (e.g., plate 216 mayhave a diameter that is smaller than or larger than the diameter ofcyclone chamber 154). The arrester plate may be coplanar with free end296 of cyclone chamber sidewall 240 (see for example FIG. 7) or is maybe axially spaced therefrom (See for example FIG. 8).

FIG. 7 shows an example in which arrester plate 216 has a diameter thatis smaller than the diameter of cyclone chamber 154 so that at least aportion of dirt outlet 190 is defined by gap lengths 292 that are solelyradial. That is, the shortest distance between at least a portion 304 ofarrester plate periphery 288 and cyclone chamber sidewall 240 is in adirection that is transverse (e.g. perpendicular) to cyclone axis 242.As shown, at least portion 304 of arrester plate periphery 288 has thesame axial position as a portion of cyclone chamber sidewall 240.

FIG. 8 shows an example in which all of dirt outlet 190 is defined bygap lengths 292 that include radial and axial components. That is, theshortest distance between at least a portion 304 of arrester plateperiphery 288 and cyclone chamber sidewall 240 is in a direction that isat a non-zero and non-perpendicular angle (i.e. non-parallel andnon-orthogonal) to cyclone axis 242.

Different points on arrester plate periphery 288 may have different dirtoutlet gap lengths 292. FIG. 9 shows an example in which arrester plate216 is off-centered relative to cyclone axis 242 whereby radial gaplength 292 is greater at some points along arrester plate periphery 288than others (e.g. compare gap length 2921 to gap length 2922).Alternatively, or in addition, arrester plate periphery 288 may have anaxial shape (i.e. the shape of a projection of arrester plate periphery288 in a direction parallel to cyclone axis 242) that differs from theaxial shape of cyclone chamber sidewall 240 where cyclone chambersidewall 240 is nearest to arrester plate periphery 288 (e.g. atriangular arrester plate periphery 288 and circular cyclone chambersidewall 240). This too may produce a variable gap length 292 aroundarrester plate periphery 288.

Returning to FIGS. 3-5, the illustrated arrester plate 216 is shownincluding an upper plateau and a peripheral step on one side. Theperipheral step can provide an enlarged dirt outlet gap length acrossonly the stepped portion of the dirt arrester periphery. An advantage ofthis design is that the enlarged dirt outlet gap provides clearance forlarge dirt particles to pass through the dirt outlet into the dirtcollection chamber while optionally maintaining a smaller gap for theremainder of the perimeter of the arrester plate (if the remainder ofthe arrester plate is spaced from sidewall 240). As compared with a dirtarrester that has a comparably large gap length about the entirearrester plate periphery, the illustrated axially stepped design maymitigate re-entry of dirt from the dirt collection chamber into thecyclone chamber through the dirt outlet because much of the dirt outletretains a relatively smaller gap length. In laboratory testing, theaxially stepped design produced greater dirt separation efficiency ascompared with a uniformly planar arrester plate, all else being equal.

As shown, arrester plate 216 includes a first portion 308 and a secondportion 312. The first and second portions 308 and 312 are axiallyspaced apart and joined together by a transition portion 316 positionedbetween the first and second portions 308 and 312. In the illustratedexample, transition portion 316 extends from first portion 308 to secondportion 312. First, second, and transition portions 308, 312, and 316may be integrally formed as shown, or discretely formed and rigidlyconnected together. At least the first and second portions 308 and 312each include a portion of arrester plate periphery 288. In theillustrated example, each of the first, second, and transition portions308, 312, and 316 include a portion of arrester plate periphery 288.

Each of first, second, and transition portions 308, 312, and 316includes a cyclone chamber face 320 ₁, 320 ₂, and 320 ₃ respectively.Cyclone chamber faces 320 border the inner volume of cyclone chamber154. As shown, second portion cyclone chamber face 320 ₂ may be axiallyspaced (i.e. in a direction parallel to cyclone axis 242) apart fromfirst portion cyclone chamber face 320 ₁ in a direction away fromcyclone first end 228. Thus, arrester plate second portion 312 forms anaxial step from the arrester plate first portion 308. As shown, theaxial separation between arrester plate first and second portions 308and 312 may provide arrester plate periphery 288 with a greater dirtoutlet gap length 292 at arrester plate second portion 312 than atarrester plate first portion 308. This allows larger particles to passthrough dirt outlet 190 at arrester plate second portion 312, whilemaintaining a smaller gap at arrester plate first portion 308 tomitigate re-entry of dirt particles from dirt collection chamber 156into cyclone chamber 154.

As shown, cyclone chamber faces 320 ₁ and 320 ₂ of arrester plate firstand second portions 308 and 312 may face towards cyclone first end 228(e.g. towards cyclone first end wall 232). In the illustrated example,cyclone chamber faces 320 ₁ and 320 ₂ are substantially planar andperpendicular to cyclone axis 242. In other embodiments, one or both ofcyclone chamber faces 320 ₁ and 320 ₂ may be non-planar. Alternativelyor in addition, one or both of cyclone chamber faces 320 ₁ and 320 ₂ maybe non-perpendicular to cyclone axis 242.

Axial separation between cyclone chamber faces 320 ₁ and 320 ₂ may bedescribed by their distances from a reference plane 324 (also referredto as a “transverse plane”), which is perpendicular to cyclone axis 242and intersects the cyclone, such as at cyclone first end 228. As shown,axial distance 322 ₂ from second portion cyclone chamber face 320 ₂ toreference plane 324 is greater than axial distance 322 ₁ from firstportion cyclone chamber face 320 ₁ to reference plane 324.

Transition cyclone chamber face 320 ₃ may extend at a non-zero angle tofirst and second portion cyclone chamber faces 320 ₁ and 320 ₂. Asshown, transition cyclone chamber face 320 ₃ may extend substantiallyaxially (e.g. substantially parallel to cyclone axis 242). In theexample shown, transition cyclone chamber face 320 ₃ extendsperpendicular to first and second portion cyclone chamber faces 320 ₁and 320 ₂. As shown, transition cyclone chamber face 320 ₃ may besubstantially planar.

In some embodiments, transition cyclone chamber face 320 ₃ may benon-perpendicular to cyclone axis 242. For example, it may extend at anacute angle to each of first and second portion cyclone chamber faces320 ₁ and 320 ₂. Alternately, or in addition, transition cyclone chamberface 320 ₃ may be non-planar; for example, it may curve from first andsecond portion cyclone chamber face 320 ₁ to second portion cyclonechamber face 320 ₂. For example, transition cyclone chamber face 320 ₃may be concave or convex.

Arrester plate second portion 312 may be smaller in size (e.g., crosssectional area in a plane parallel to reference plane 324) than arresterplate first portion 308. An advantage of this design is that it providesarrester plate with an enlarged dirt outlet gap length 292 across lessthan half of dirt outlet 190. For example, the area of an axialprojection of arrester plate second portion 312 may be smaller (e.g.,less than 50%, less than 40%, less than 30%, less than 20% or less than10%) than the area of an axial projection of arrester plate firstportion 308. In the illustrated example, the area of an axial projectionof arrester plate second portion 312 is less than one-half of the areaof an axial projection of arrester plate first portion 308. In addition,arrester plate second portion 312 may include less of arrester plateperiphery 288 than arrester plate first portion 308 (e.g., less than50%, less than 40%, less than 30%, less than 20% or less than 10%). Inthe illustrated example, arrester plate second portion 312 includes lessthan one quarter of arrester plate periphery 288.

Arrester plate second portion 312 may be laterally offset (i.e. in adirection perpendicular to cyclone axis 242) from cyclone axis 242. Asshown, arrester plate second portion 312 is axially spaced from arresterplate first portion 308 along an axial line 326 that is parallel andlaterally spaced from cyclone axis 242.

Transition cyclone chamber face 320 ₃ may meet first and second portioncyclone chamber faces 320 ₁ and 320 ₂ at first and seconddiscontinuities 328 ₁ and 328 ₂ respectively. As shown, transitioncyclone chamber face 320 ₃ extends between first and seconddiscontinuities 328 ₁ and 328 ₂. First discontinuity 328 ₁ may bepositioned between first portion cyclone chamber face 320 ₁ andtransition portion cyclone chamber face 320 ₃, and second discontinuitymay be positioned between second portion cyclone chamber face 320 ₂ andtransition portion cyclone chamber face 320 ₃.

As used herein, a “discontinuity” is a macro-scale deviation ordisruption of a surface pattern or shape pattern. For example, firstdiscontinuity 328 ₁ is shown as a 90 degree bend that is a deviationfrom the planar surface of first portion of cyclone chamber face 320 ₁,and second discontinuity is shown as a 90 degree bend that is adeviation of the planar surface of second portion of cyclone chamberface 320 ₂. Minor deviations (e.g. seams and clearance gaps betweenotherwise continuous portions), and micro deviations (e.g. elements ofsurface texture) are not considered herein to be discontinuities. Itwill be appreciated that, instead of a 90 degree bend, thediscontinuities may be rounded.

It will be appreciated that arrester plate 216 may have a perimeterwithout any angles or other discontinuities. Arrester plate periphery288 may therefore have a continuous axial shape (i.e. the shape of aprojection of arrester plate periphery 288 in a direction parallel tocyclone axis 242) that is smooth. Accordingly, as shown in plan view inFIG. 9, arrester plate 216 is circular.

It will be appreciated that arrester plate may be of any other shapesuch as elliptical or polygonal (e.g., hexagonal, square, triangle orthe like). For example, as exemplified in FIG. 10, an arrester plateperiphery 288 may have a discontinuous axial shape. In the exampleshown, arrester plate periphery 288 has first and second portions 332and 336 connected by two discontinuities 340. Discontinuities 340provide deviations from the regular (e.g. circular) shape of peripheryfirst portion 332, and the regular (e.g. linear) shape of peripherysecond portion 336. In this example, discontinuities 340 are corners(also referred to as junctures) between first and second portions 332and 336.

It will be appreciated that arrester plate 216 may have an irregularperimeter. For example, the arrester plate may have a shape wherein partof the plate has been truncated to increase the size of the dirt outletgap. The truncated portion may be any portion of the plate and may beprovided on the second portion. This feature may be used with any platethat has a smooth perimeter or which has a perimeter withdiscontinuities.

For example, as exemplified in FIG. 10, first and second discontinuities3401 and 3402 may be provided on arrester plate second portion 312. Forexample, second portion 336 of arrester plate periphery 288 may borderat least a portion of arrester plate second portion 312. As compared toarrester plate 216 were the axial shape of periphery first portion 332continuous around the entire arrester plate periphery 288 (e.g. fullycircular), a plate segment 344 has been removed where periphery secondportion 336 truncates the axial shape of periphery first portion 332. Asshown, periphery second portion 336 may be formed as a cord (e.g. linearcrop) to the circular axial shape of periphery first portion 332. Theremoval of plate segment 344 may further enlarge dirt outlet gap lengths292 at arrester plate second portion 312. This allows arrester plate 216to allow even larger particles to pass through the portion of dirtoutlet 190 located between periphery second portion 336 and cyclonesidewall 240, as compared to the same arrester plate 216 with platesegment 344 intact.

It will be appreciated that an arrester plate 216 with an axial step cancreate a concave (also referred to as ‘hollow’) step volume behind theaxial face of the step. Depending on the manner in which the associatedcyclone and dirt collection chambers are emptied, fibrous debris (e.g.hair) may snag or accumulate in the step volume when emptying thesurface cleaning apparatus. Alternately, a hollow shape of the dirtchamber facing side of plate 216 may create eddy currents or otherwiseinterfere with dirt settling in the dirt collection chamber. Therefore,in some embodiments the step volume is closed by the dirt chamber faceof the arrester plate. Closing the hollow step volume may be used withany axially stepped arrester described herein.

It will be appreciated that the closure portion may underlie or traverseonly the transition portion, (e.g., if the transition portion extends atan angle to reference plane 324). Alternately, the closure portion mayunderlie both the transition portion and one or both of the first andsecond portions. As exemplified in FIGS. 11-19, the closure portionunderlies both the transition portion and the first portion. Anadvantage of this design is that the axial thickness of the secondportion is not increased. It will be appreciated that the more of thefirst portion that the closure portion underlies, the more gradual theangle of the closure portion may be.

Referring to FIGS. 4-5, an example arrester plate 216 is shown includingan open step volume 348. Step volume 348 is a hollow volume behindtransition portion dirt chamber face 3643. As shown, step volume 348 isbordered by transition portion 316 to one side and by first portion 308above.

FIGS. 11-13 exemplify an embodiment of arrester plate 216 in which stepvolume 348 is closed by a closure portion 352 of dirt chamber face 224.As shown, closure portion 352 may be opposed to transition portioncyclone chamber face 320 ₃ and to at least a portion of first portion ofcyclone chamber face 320 ₁. By closing step volume 348, a smoother dirtchamber face of plate 216 is provided which may reduce eddy currents inthe dirt collection chamber and facilitate dirt settling in the dirtcollection chamber and not being reintrained into the cyclone chamber.

Closure portion 352 may have any configuration suitable to close stepvolume 348. In some embodiments, closure portion 352 may be free ofconcavities (e.g. entirely planar as shown, entirely convex, or includeboth planar and convex portions). In the illustrated example, closureportion 352 extends from a first end 356 proximate dirt chamber face3642 of second portion 312 towards or across cyclone axis 242 to secondend 360 within dirt chamber face 3641 of first portion 308.

FIGS. 11-13 exemplify an example in which closure portion second end 360is proximate cyclone axis 242. FIGS. 14-16 exemplify an example ofarrester plate 216 in which cyclone axis 288 is located between closureportions first and second ends 356 and 360. FIGS. 17-19 exemplifyanother example of arrester plate 216 in which cyclone axis 288 islocated between closure portions first and second ends 356 and 360.

Closure portion 352 may extend transverse (i.e. non-parallel) to cycloneaxis 242. For example, FIGS. 11-13 and 14-16 show examples of arresterplate 216 in which closure portion 352 is neither parallel norperpendicular to cyclone axis 242. As shown, closure portion first end356 may be axially and laterally spaced apart from closure portionsecond end 360. In the illustrated example, closure portion first end356 is axially spaced from closure portion second end 360 away fromcyclone chamber first end 228. FIGS. 17-19 show an example of arresterplate 216 in which closure portion first end 356 is axially aligned andlaterally spaced apart from closure portion second end 360.

Referring again to FIGS. 11-13, closure portion 352 may be oriented sothat it diverges from cyclone chamber face 320 ₃ of transition portion316 in a direction away from arrester plate second portion 312. Asshown, closure portion second end 360 may be spaced farther from cyclonechamber face 320 ₃ of transition portion 316 than closure portion firstend 356.

Dirt chamber face 224 may have one or more discontinuities. For example,FIGS. 11-13 and 14-16 illustrate arrester plates 216 having a dirtchamber face 224 with a discontinuity 368 at the juncture of closureportion 352 and dirt chamber face 3642 of second portion 312. Thediscontinuity is preferably rounded so as to avoid a sharp angle. Inother embodiments, dirt chamber face 224 may be entirely continuous. Forexample, FIGS. 17-19 show an arrester plate 216 having a dirt chamberface 224 that is entirely planar. In the illustrated example, dirtchamber face 224 is perpendicular to cyclone axis 242. In otherembodiments, dirt chamber face 224 may be oriented non-perpendicular andnon-parallel to cyclone axis 242.

Plate first portion 308 may have an axial thickness 3721 greater thanaxial thickness 3722 of plate second portion 312. FIGS. 17-19 show anexample arrester plate 216 having a plate first portion 308 with auniform thickness 3721 that is greater than thickness 3722 of platesecond portion 312. FIGS. 11-13 and 14-16 show example arrester plates216 having a plate first portion 308 with a thickness 3721 thatincreases towards transition portion 316. As shown, plate thickness 3721may increase between closure portion first and second ends 356 and 360towards first end 356.

Radially Extending Gap

In accordance with this feature, the dirt collection chamber is externalto the cyclone chamber and the dirt outlet from the cyclone chambercomprises or consists of a radially extending gap between the arresterplate and the cyclone chamber sidewall. In accordance with this feature,at least one part of the arrester plate is recessed inwardly such that,for a portion of the perimeter of the plate, a larger radial distance isprovided between the cyclone chamber sidewall and the perimeter of theplate. Providing the larger radial distance may create a relativelylarger dirt outlet gap between the cyclone chamber sidewall and therecessed part of the arrester plate periphery, which can allow largerdebris to pass through the dirt outlet.

Without being limited by theory, as compared with an entirely circulararrester plate which provides a generally uniformly sized dirt outletgap, varying the radial gap may provide greater separation efficiency(i.e. percentage of dirt particles of a dirty air flow separated fromthe air flow and retained in the dirt collection chamber) by permittinglarger dirt particles to exit the cyclone chamber thereby reducing thelikelihood that larger dirt particles in the cyclone chamber may produceeddy currents or otherwise interfere with the flow pattern in a cyclonechamber. Thus, a radially variable arrester design may allow the dirtcollection chamber to admit large dirt particles (e.g. stones, dryfoods, etc.) while providing a high separation efficiency.

In accordance with this design, the spacing generally may include afirst portion that extends around a first portion of the perimeter ofthe plate and a second portion that extends around a second portion ofthe perimeter of the plate wherein the second portion of the spacing hasa larger length in a radial direction in a plane of the plate than thefirst portion of the spacing. The larger length may be produced by asecond part of the plate having the second portion of the perimeterhaving a different diameter or shape than a first part of the platehaving the first portion of the perimeter.

It will be appreciated that, in addition, the second part of the platemay have a greater distance between the cyclone chamber face of theplate and the first or inlet end of the cyclone chamber than a distanceof the first part of the plate and the first end of the cyclone chamber.Alternately, or in addition, the axial length of the cyclone chambersidewall may vary around the perimeter of the cyclone chamber sidewall.

FIGS. 20 to 24 show an example of cyclone bin assembly having botharrester plate 216 and cyclone chamber sidewall 240 shaped to define acyclone dirt outlet 190 formed by both an radially extending gap and avertically extending gap between cyclone chamber sidewall 240 and thearrester plate 216. Accordingly, the size of the gap varies around theperimeter of the arrester plate 216 and it also varies in differentdirections.

As exemplified in FIGS. 20 and 23A, a first part 380 of arrester plate216 has a diameter D₁ that is smaller than the diameter D₃ of cyclonechamber 154 and, a second part 381 of arrester plate 216 has a diameterD₂ that is larger than the diameter D₁ of first part 380, and may be thesame or larger than the diameter D₃ of cyclone chamber 154. Referring toFIG. 21, it can be seen that a projection of the cyclone chambersidewall 240 does not intersect first part 380 of arrester plate 216(the first part of the plate is located radially inwardly of the cyclonechamber sidewall) but intersects the second part 381 of arrester plate216 (the perimeter of the second part of the plate underlies the freeend 296 of cyclone chamber sidewall 240, e.g., an extension of thesidewall would intersect the outermost end of the second part of theplate). Further, as exemplified in FIG. 21, the cyclone chamber face 220may be in the plane defined by the free end 296 of the portion ofcyclone chamber sidewall 240 having length L₂. Accordingly, along theperimeter of first part 380, a first portion of the dirt outlet 190 isdefined solely by a radially extending gap having a radial gap length292 a. However, along the perimeter of second part 381, a first lengthL₁ of the cyclone chamber sidewall 240 is shorter than a second lengthL₂ of the cyclone chamber sidewall 240 at the first part of theperimeter of the arrester plate 216. As exemplified, a shorter length L₁is provided by a vertical or axially extending edge 383, of the sidewall240 so as to provide a vertical recess 384. Accordingly, along theperimeter of second part 381, a second portion of the dirt outlet 190 isdefined solely by a vertically extending gap between the cyclone chamberface 220 and the free end 296 of cyclone chamber sidewall 240, which hasa vertical gap length 292 b. Accordingly, the spacing between thecyclone chamber sidewall and the plate around the first part of theperimeter is larger than the spacing between the cyclone chambersidewall and the plate around the second part of the perimeter andtherefore, the spacing has a larger length in the radial direction.Concurrently, due to the vertical recess 384, the spacing around thesecond portion of the plate in the vertical direction of the plane ofthe sidewall (the direction of the cyclone axis) has a longer lengththan the first part of the plate.

As further shown in FIG. 22, the free end 296 of cyclone chambersidewall 240 may also have a shorter length along a portion of theperimeter of first part 380. Accordingly, along this part of theperimeter, a third portion of the dirt outlet 190 is formed by both aradially extending gap having a radial gap length 292 a and a verticallyextending gap having a vertical gap length 292 b. Accordingly, for thisthird portion of the dirt outlet 190, the gap length 292 thereforeequates to the shortest distance between the perimeter of the arresterplate 216 and the cyclone chamber sidewall 240 and is generallynon-perpendicular to the chamber facing surface of the arrester plate216 and non-planar with the cyclone chamber sidewall 240.

It will be appreciated that by providing a radially recessed first part380 of plate 216, a smaller dirt outlet gap length 292 is provided forpart of the perimeter of the plate, while varying the length of thecyclone chamber sidewall 240 may provide, alone or in conjunction withthe recessed first part 380 of the plate, a larger dirt outlet gaplength 292 for another part of the perimeter of the plate.

As exemplified in FIG. 23A, the first part 380 of the arrester plate216, which has a diameter that is less than the diameter of the cyclonechamber 154, is generally linear. It will be appreciated that this partneed not be linear but may be curved (e.g., concave is shape) or may bestepped inwardly so as to define a recess 382. It will also beappreciated that only portion of this part may be generally linear orcurved. As also exemplified, the second part (the front and rear partsas exemplified) of plate 216 are curved. The front and rear parts mayhave the same curvature or radius or, as exemplified, they may differ.However, the perimeter of part or all of the second part need not becurved. As exemplified in FIGS. 32A and 32B, part of the perimeter ofthe second part (the front of plate 216) is linear so as to define agenerally D-shaped plate 216.

It will also be appreciated that, in an alternate embodiment, all of thecyclone chamber face 220 may be spaced axially from the plane defined bythe free end 296 of the portion of cyclone chamber sidewall 240 havinglength L₂ in a direction away from first end 228.

As exemplified in FIG. 25, some of plate 216 may be spaced axially fromthe plane defined by the free end 296 of the portion of cyclone chambersidewall 240 having length L₂ in a direction towards first end 228. Inthis example, a portion of the cyclone chamber sidewall 240 extendsbelow the top surface of the arrester plate 216 such that a radialprojection of the top surface of the arrester plate 216 intersects thecyclone chamber sidewall 240. In this example, at the part of thearrester plate 216 where the portion of the cyclone chamber sidewall 240extends below the top surface is at a rear part of the arrester plate216, but it should be understood that any portion of the cyclone chambersidewall 240 may extend below the top surface of the arrester plate 216.A radially extending gap having a radial gap length 292 a is shown atthe rear part of the arrester plate 216. It will be appreciated that avertically extending gap having a gap length 292 b is provided at theportion of the cyclone chamber sidewall that extends below the topsurface of the of the arrester plate 216. In this manner, a piece ofdebris passing from the cyclone chamber 154 to the dirt collectionchamber 156 passes over perimeter of the arrester plate 216 and downwardthrough the radially extending portion of the gap to the dirt collectionchamber.

It will be appreciated that the transition between the first length L₁of the cyclone chamber sidewall 240 and the second length L₂ of thecyclone chamber sidewall 240 can be anywhere along the perimeter of thearrester plate 216.

As also exemplified in FIGS. 25 and 26, a variable length of the cyclonechamber sidewall 240 may be provided by other than having an axiallyextending edge 383. For example, as exemplified in FIGS. 25 and 26, freeend 296 of cyclone chamber sidewall 240 may extend at an angle to thecyclone axis (free end 196 of the cyclone chamber sidewall 240 may havea constantly, e.g. linearly, increasing length between the first part ofthe arrester plate 216 and the second part of the arrester plate 216).Alternately, as exemplified in FIG. 29, only a portion of free edge 296may be at an angle or, as exemplified in FIG. 31, it may be curved so asto provide a curved transition.

In the embodiment of FIG. 25, plate 216 may have a length such that afront part of the arrester plate 216 extends to the cyclone chambersidewall 240 such that a projection of the cyclone chamber sidewall 240intersects the arrester plate 216. If plate 216 has the same shape asshown in FIG. 23B, then along the perimeter of second part 381, only avertical gap may be provided. An annular and a vertical gap may beprovided along the perimeter of first part 380. It should be noted thatthe vertically extending gap having a vertical gap length 292 b at thefront part of the arrester plate 216 and the vertically extending gaphaving a vertical gap length 292 b at the rear part of the arresterplate 216 may have same or different vertical gap lengths.

In the embodiment of FIG. 26, plate 216 may extend forwardly the sameamount as in FIG. 25 such that the front part of the arrester plate 216extends to the cyclone chamber sidewall 240 such that a projection ofthe cyclone chamber sidewall 240 intersects the arrester plate 216.However, in this embodiment, unlike FIG. 25, a rear part of the plateabuts the rear part of cyclone chamber sidewall 240. In this example,the constantly increasing length of the cyclone chamber sidewall 240begins at the front part of the arrester plate 216 where the gap formingthe cyclone dirt outlet 190 includes a vertically extending gap having avertical gap length 292 b. The vertical gap length 292 b then decreasesin length along the arrester plate 216 towards a rear part of thearrester plate 216, terminating at the rear part of the arrester plate216 where the vertical gap length 292 b is zero. If plate 216 has thesame shape as shown in FIG. 23B, then along the perimeter of second part381, only a vertical gap may be provided. An annular and a vertical gapmay be provided along the perimeter of first part 380, except for thepart that abuts the cyclone chamber sidewall 240. It will be appreciatedthat plate 216 may be axially spaced from free end 196 of the cyclonechamber sidewall 240 so as to define a smaller vertical gap 292 b at therear end of plate 216.

FIG. 27 exemplifies an embodiment similar to that of FIG. 21. However,unlike the embodiment of FIG. 21, plate 26 has a diameter that is thesame as the diameter of the cyclone chamber. As cyclone chamber face 220is in the plane defined by the free end 296 of the portion of cyclonechamber sidewall 240 having length L₂, in the embodiment of FIG. 27, therear end of plate 216 abuts the free end of cyclone chamber sidewall 240in a similar manner to what is shown in FIG. 26. It will be appreciatedthat plate 216 may be axially spaced from free end 196 of the cyclonechamber sidewall 240 so as to define a smaller vertical gap 292 b at therear end of plate 216.

It will be appreciated that two or more larger portions of the dirtoutlet 190 may be provided. For example, as exemplified in FIG. 22, tworecesses 384 may be provided instead of or in addition to the largerdirt outlet provided by the vertical recess 384, in the cyclone chambersidewall. Alternately, two or more vertical recesses 384, may beprovided. Examples of such embodiments are provided in FIGS. 28 and 30.

As exemplified in FIG. 28, the cyclone dirt outlet 190 comprises a firstcyclone dirt outlet portion 190 a and a second cyclone dirt outletportion 190 b. As exemplified, the first cyclone dirt outlet portion 190a is formed at a front part of the arrester plate 216 and the secondcyclone dirt outlet portion 190 b is formed at a rear part of thearrester plate 216. The first cyclone dirt outlet portion 190 a isformed by a vertically extending gap having a vertical gap length 292 band the second cyclone dirt outlet portion 190 b is formed by avertically extending gap also having a vertical gap length 292 b. Itshould be noted that the first cyclone dirt outlet portion 190 a and thesecond cyclone dirt outlet portion 190 b may be the same as exemplifiedor they may have different vertical gap lengths. The first cyclone dirtoutlet portion 190 a and the second cyclone dirt outlet portion 190 bare separated by a second portion 386 of the cyclone chamber sidewall240 having a length L₂ that is longer than the length L₁ of a firstportion 385 of the cyclone chamber sidewall 240 defining the cyclonedirt outlets portion 190 a, 190 b. As exemplified, the length L₂ of thesecond portion 386 of the cyclone chamber sidewall 240 extends to thesecond part of the arrester plate 216 where the vertical gap length 292b is zero (i.e. the free end 296 of cyclone chamber sidewall 240 abutsthe arrester plate 216). It will be appreciated that plate 216 may beaxially spaced from free end 296 of the cyclone chamber sidewall 240 soas to define a smaller vertical gap 292 b at this location.

In the example shown in FIG. 28, the transitions between the firstlength of the cyclone chamber sidewall 240 and the second length of thecyclone chamber sidewall 240 are generally vertical and can be anywherealong the perimeter of the arrester plate 216. Alternately, asexemplified in FIG. 29, the transition between the first length of thecyclone chamber sidewall 240 and the second length of the cyclonechamber sidewall 240 need not be vertical but rather may be gradual. Forexample, as exemplified, free end 296 may extend linearly at an angle tothe cyclone axis such that the length of the first portion of thecyclone chamber sidewall 240 gradually increases in a linear fashion asthe cyclone chamber sidewall 240.extends towards a rear part of thearrester plate 216. Alternately, free end 296 may be curved asexemplified in FIG. 31).

It will also be appreciated that a portion of plate 216 may extendradially outwardly of cyclone chamber sidewall 240. Also exemplified inFIGS. 29 and 31, the front part of the arrester plate 216 extends beyonda projection of the cyclone chamber sidewall 240 such that theprojection of the cyclone chamber sidewall 240 intersects the arresterplate 216. If plate 216 has the same shape as shown in FIG. 23B, then atthe front of the cyclone chamber, the cyclone dirt outlet 190 is formedby a vertically extending gap having a vertical gap length 292 b and aradially extending gap having a radial gap length 292 a is providedalong the lateral sides of the plate 216.

It will be appreciated that, in any of the forging embodiments, thesecond part of the perimeter of the plate 216 may have a greaterdistance between the cyclone chamber face of the plate 216 and the firstend of the cyclone chamber 154 than a distance of the first part of theplate 216 and the first end of the cyclone chamber 154. For example,FIGS. 33A to 39B show further examples of cyclone bin assemblies whereina variable sized dirt outlet is provided using an axially stepped plate216 and a cyclone chamber sidewall 240 having a variable length.Optionally, as shown in these examples, the plate 216 may have differentdiameters in different directions (as exemplified in FIG. 23B and/orradially inward recesses as exemplified in FIG. 22. Accordingly, inFIGS. 33A to 39B cyclone dirt outlet 190 is formed at least partially bya vertically extending gap and a radially extending gap between cyclonechamber sidewall 240 and the arrester plate 216. In these examples, theshape of the cyclone chamber sidewall 240 and the shape of the arresterplate 216 each vary to define the gap forming cyclone dirt outlet 190.

In the example shown in FIGS. 33A and 33B, a front part of the arresterplate 216 is vertically stepped downwardly (as previously described) andthe front portion of the cyclone chamber sidewall 240 has a shorterlength than a rear portion of the cyclone chamber sidewall, therebycreating a vertically extending gap of vertical gap length 292 b ₂ atthe front part of the arrester plate 216 and a vertically extending gapof vertical gap length 292 b ₁ at a side part of the arrester plate 216rearward of the vertical step of the arrester plate 216. In addition, asthe plate is shaped like the plate exemplified in FIG. 23B, a radialextending gap of radial gap length 292 a is also provided on the lateralsides of plate 216. Accordingly, the spacing between the cyclone chambersidewall and the plate around the first part of the perimeter is largerthan the spacing between the cyclone chamber sidewall and the platearound the second part of the perimeter and therefore, the spacing has alarger length in the radial direction. Concurrently, due to the steppedarrester design, the spacing around the second portion of the plate inthe vertical direction of the plane of the sidewall (the direction ofthe cyclone axis) has a longer length than the first part of the plate.

In the example shown in FIGS. 34A and 34B, part of the forward part ofthe arrester plate 216 that is vertically stepped downwardly (aspreviously described) extends beyond (radially outwardly of) aprojection of the front portion of the cyclone chamber sidewall 240.Accordingly, the dirt outlet comprises a radial extending gap of radialgap length 292 a that is provided on the lateral sides of plate 216, avertically extending gap of vertical gap length 292 b ₁ at the sides ofthe forward part of the plate 216 and a larger vertically extending gapof vertical gap length 292 b ₂ at the front of the forward part of theplate 216. It will be appreciated that gap length 292 b ₁ may be largerthan gap length 292 b ₂.

The example shown in FIGS. 35A and 35B is similar to that of FIGS. 34Aand 34B except that the entirety of the forward part of the arresterplate 216 that is vertically stepped downwardly (as previouslydescribed) extends beyond a projection of the front portion of thecyclone chamber sidewall 240. Accordingly the dirt outlet comprises aradial extending gap of radial gap length 292 a that is provided on thelateral sides of plate 216, a vertically extending gap of vertical gaplength 292 b ₁ at the sides of the forward part of the plate 216 and ashorter vertically extending gap of vertical gap length 292 b ₂ at thefront of the forward part of the plate 216.

The example shown in FIGS. 36A and 36B is similar to that of FIGS. 34Aand 34B except that only the stepped down portion underlies the freeedge 296 of the cyclone chamber sidewall such that the vertical gap isdefined between the stepped down portion and the free edge 296.

The example shown in FIGS. 37A and 37B is similar to that of FIGS. 34Aand 34B except that transition portion 316 underlies the free edge 296of the cyclone chamber sidewall.

The example shown in FIGS. 38A and 38B is similar to that of FIGS. 34Aand 34B except that all of the stepped down portion is positionedradially outwardly of the cyclone chamber sidewall 240.

In the example shown in FIGS. 39A and 39B, the front part of thearrester plate 216 is vertically sloped downwardly and towards the frontof the cyclone chamber assembly to form the vertically extending gap ofvertical gap length 292 b 2 at the front part of the arrester plate 216.

While the above description provides examples of the embodiments, itwill be appreciated that some features and/or functions of the describedembodiments are susceptible to modification without departing from thespirit and principles of operation of the described embodiments.Accordingly, what has been described above has been intended to beillustrative of the invention and non-limiting and it will be understoodby persons skilled in the art that other variants and modifications maybe made without departing from the scope of the invention as defined inthe claims appended hereto. The scope of the claims should not belimited by the preferred embodiments and examples, but should be giventhe broadest interpretation consistent with the description as a whole.

1. A surface cleaning apparatus comprising: (a) an air flow pathextending from a dirty air inlet to a clean air outlet; (b) a cycloneand a suction motor provided in the air flow path; (c) the cyclonecomprising a cyclone chamber having a central longitudinal axis, thecyclone having a first end having a first end wall, an axially spacedapart second end, a cyclone chamber sidewall located between the firstand second ends, a cyclone air inlet provided at the first end, acyclone air outlet provided at the first end and a dirt outlet providedat the second end, wherein the first end of the cyclone chamber sidewallis located at the first end of the cyclone and the second end of thesidewall is spaced from the first end; (d) a plate located at the secondend, the plate having a plate perimeter, a cyclone chamber face thatfaces towards the first end; and, (e) a dirt collection region incommunication with the cyclone chamber via the dirt outlet, wherein thedirt outlet comprises a spacing between the cyclone chamber sidewall andthe plate, and the plate has a non-circular shape in a plate plane thatis transverse to the central longitudinal axis and that is located atthe plate.
 2. The surface cleaning apparatus of claim 1 wherein thecyclone chamber sidewall is circular.
 3. The surface cleaning apparatusof claim 1 wherein a cyclone chamber end plane that is transverse to thecentral longitudinal axis is located at the second end of the cycloneand the second end of the cyclone has a shape in the cyclone chamber endplane and the plate has a shape in the plate plane that differs to theshape of the second end of the sidewall.
 4. The surface cleaningapparatus of claim 3 wherein the cyclone chamber sidewall is circular.5. The surface cleaning apparatus of claim 3 wherein the shape of theplate is oval.
 6. The surface cleaning apparatus of claim 5 wherein thecyclone chamber sidewall is circular.
 7. The surface cleaning apparatusof claim 3 wherein the shape of the plate is D-shaped.
 8. The surfacecleaning apparatus of claim 7 wherein the cyclone chamber sidewall iscircular.
 9. The surface cleaning apparatus of claim 3 wherein the platehas a recess that extends inwardly in the plate plane.
 10. The surfacecleaning apparatus of claim 9 wherein the cyclone chamber sidewall iscircular.
 11. The surface cleaning apparatus of claim 3 wherein theshape of the plate is polygonal.
 12. The surface cleaning apparatus ofclaim 11 wherein the cyclone chamber sidewall is circular.
 13. Thesurface cleaning apparatus of claim 1 wherein the spacing comprises afirst portion that extends around a first portion of the perimeter and asecond portion that extends around a second portion of the perimeter,wherein the second portion of the spacing has a larger length in aradial direction in the plate plane.
 14. The surface cleaning apparatusof claim 13 wherein a second part of the plate has a greater distancebetween the cyclone chamber face of the plate and the first end of thecyclone chamber than a distance of a first part of the plate and thefirst end of the cyclone chamber.
 15. The surface cleaning apparatus ofclaim 1 wherein a second part of the plate has a greater distancebetween the cyclone chamber face of the plate and the first end of thecyclone chamber than a distance of a first part of the plate and thefirst end of the cyclone chamber.
 16. The surface cleaning apparatus ofclaim 1 wherein the dirt collection region is located below the plateand the dirt collection region has a lower wall that extends in a planethat is at a non-zero and non-perpendicular angle to the centrallongitudinal axis.
 17. A surface cleaning apparatus comprising: (a) anair flow path extending from a dirty air inlet to a clean air outlet;(b) a cyclone and a suction motor provided in the air flow path; (c) thecyclone comprising a cyclone chamber having a central longitudinal axis,the cyclone having a first end having a first end wall, an axiallyspaced apart second end, a cyclone chamber sidewall located between thefirst and second ends, a cyclone air inlet provided at the first end, acyclone air outlet provided at the first end and a dirt outlet providedat the second end, wherein the first end of the cyclone chamber sidewallis located at the first end of the cyclone and the second end of thesidewall is spaced from the first end; (d) a plate located at the secondend, the plate having a plate perimeter, a cyclone chamber face thatfaces towards the first end; and, (e) a dirt collection region incommunication with the cyclone chamber via the dirt outlet, wherein thedirt outlet comprises a spacing between the cyclone chamber sidewall andthe plate, and wherein a cyclone chamber end plane that is transverse tothe central longitudinal axis is located at the second end of thecyclone and the second end of the cyclone has a shape in the cyclonechamber end plane, and wherein a plate plane that is transverse to thecentral longitudinal axis and that is located at the plate, and theplate has a shape in the plate plane, and the plate has a shape in theplate plane that differs to the shape of the second end of the sidewall.18. The surface cleaning apparatus of claim 17 wherein a second part ofthe plate has a greater distance between the cyclone chamber face of theplate and the first end of the cyclone chamber than a distance of afirst part of the plate and the first end of the cyclone chamber. 19.The surface cleaning apparatus of claim 17 wherein the shape of theplate is oval.
 20. The surface cleaning apparatus of claim 17 whereinthe shape of the plate is polygonal.